Handheld dimensioning system with measurement-conformance feedback

ABSTRACT

A system and method for obtaining a dimension measurement that conforms to a conformance criteria is disclosed. The dimensioning system provides either (i) feedback to confirm that the measurement complies with the criteria or (ii) information on how the measurement geometry could be adjusted in order to provide a compliant measurement in a subsequent dimension measurement.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. patent application Ser. No. 14/519,249 for a Handheld Dimensioning System with Measurement-Conformance Feedback filed Oct. 21, 2014 (and published Apr. 21, 2016 as U.S. Patent Publication No. 2016/0109219), now U.S. Pat. No. 9,897,434. Each of the foregoing patent application, patent publication, and patent is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to dimensioning systems, and in particular, to a handheld dimensioning system that can provide feedback relating to a dimension measurement's conformance with a measurement-accuracy criteria.

BACKGROUND

Dimensioning is the process of measuring the cubic space that an object (e.g., package) occupies. Automatic dimensioning systems may be used for calculating an object's dimensional weight to facilitate storage, handling, transporting, and/or invoicing. Transport vehicles and storage units, for example, have both volume and weight capacity limits. They can become full before they reach their weight capacity leading to inefficiencies. By dimensioning objects, parcels, and pallets, shipping companies and warehouses can make optimal use of space and charge for services accordingly. As a result, dimensioning systems that help gather this information without causing a disruption in the workflow are highly desirable. As these devices become increasingly part of commercial processes, their accuracy becomes an important characteristic to understand.

Standards have been developed for weights and measures. These standards promote a healthy business and consumer climate by providing specifications to insure uniform and equitable measurements. Measurement devices that comply with these specifications are trusted and useful tools for commerce.

Handheld dimensioners may be used for automatically determining the dimensions of a package without manually manipulating the package. The measurement environments for this type of dimensioner are highly varied, and as a result the accuracy (i.e., the minimum dimension that can be measured) of the handheld dimensioner may vary for different measurement circumstances. Industry standards require that dimension measurements conform to an accuracy criteria, however it is easy for a typical user to violate these criteria when using a handheld dimensioner. For example, when a user tries to measure a small package at a large distance then the accuracy of the measurement may violate the specifications of the standard. Here, a more accurate measurement (i.e., conforming to the standard) could be made if the handheld dimensioning system was moved closer and the measurement was repeated.

Therefore, a need exists for a handheld dimension system that automatically provides measurement-conformance feedback so the handheld dimensioning system's measurements remain in conformance.

SUMMARY

Accordingly, in one aspect, the present invention embraces a method for generating measurement-conformance feedback using a handheld dimensioning system. The method includes the step of using a dimensioning-system image-sensor to capture at least one image an object (or objects) in the handheld dimensioning system's field-of-view. A dimensioning system processor then uses this image (or images) to compute a measurement geometry. The processor uses the measurement geometry to derive a measurement accuracy, and then identify at least one conformance criteria based on this measurement accuracy. The captured image is then used by the dimensioning-system processor to obtain a dimensioning measurement. By comparing the dimension measurement to the conformance criteria, the dimensioning-system processor may generate measurement-conformance feedback corresponding to the results of this comparison.

In an exemplary embodiment, the method's measurement-conformance feedback includes an adjustment message. The adjustment message provides instructive prompts to facilitate the adjustment of the measurement geometry in order to achieve measurement conformance.

In another aspect, the present invention embraces a handheld dimension system that provides measurement conformance feedback. The dimensioning system includes an imaging subsystem. The imaging subsystem uses at least one image sensor to capture an image of an object (or objects) within a field-of-view. The image sensor (or sensors) are communicatively coupled to a control subsystem. The control subsystem includes a processor (or processors) and at one non-transitory storage medium that can store information and processor-executable instructions. These processor-executable instructions configure the processor to receive images from the image sensor (or sensors) and compute (using these received images) a measurement geometry. A measurement accuracy corresponding to the measurement geometry is then derived and a conformance criteria based on this measurement accuracy is identified. The processor-executable instructions next configure the processor to use the received images to obtain a dimension measurement. By comparing the dimension measurement to the identified conformance criteria, measurement-conformance feedback is generated.

In an exemplary embodiment, the handheld dimensioning system's conformance criteria is in compliance with the specifications for dimension measuring devices described in the 2013 edition of the NIST Handbook 44, section 5.58 and is hereby incorporated by reference.

The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts the measurement geometry.

FIG. 2 schematically depicts a block diagram of an exemplary dimensioning system.

FIG. 3 schematically depicts a flow chart of an exemplary method for generating measurement-conformance feedback.

DETAILED DESCRIPTION

The present invention embraces a handheld dimensioning system capable of providing measurement-conformance feedback regarding the accuracy of the measurement.

Dimensioning is the process of remotely measuring an object's dimensions using a dimensioning system (i.e., dimensioner). Typically, the object analyzed is a cubic package and the dimension measured is the object's volume. Measuring a package's volume is especially important in the shipping and warehousing industries, which may have space and/or weight restrictions. For example, the cost to ship a package has historically been based on the package's weight. Charging by weight alone, however, may cause a shipment of a lightweight package with a large volume to become unprofitable. As a result, dimension measurements are often required to compute shipping costs.

Dimensioning systems may be static in the sense that a package is unmoving during a measurement. Alternatively, a dimensioning system may be dynamic where the package moves during measurement (e.g., moving along a conveyor). In both of these cases, the dimensioning system is typically mounted in a fixed position and the imaging environment is carefully controlled. The most promising dimensioning system configuration, however, is handheld, which could adapt to almost any environment.

Handheld dimensioning is a challenging problem. In handheld applications, the environment is uncontrolled and the dimensioner must accommodate a range of measurement conditions, including lighting, motion, and the measurement geometry (e.g., spatial relationships and orientations). In addition, handheld applications typically have a low tolerance for excessive measurement times or alignment complexities. Thus, the sensing technology chosen for such applications must accommodate these issues.

A variety of sensing technologies have been employed for dimensioning. One exemplary sensing technology uses a three-dimensional (i.e., 3D) camera to obtain depth information. 3D cameras use the displacement in the apparent position of an object when viewed along two lines of sight (i.e., parallax) to derive depth information.

Another exemplary sensing technology uses structured light. Structure light is the process of projecting a known light pattern (e.g., dots, grids, bars, stripes, checkerboard, etc.) onto a scene (i.e., field of view). A pattern image is then captured by an image sensor and distortions in the pattern caused by objects in the field-of-view can be analyzed to derive depth information.

Yet another exemplary sensing technology uses time-of-flight (TOF) to determine depth information. Here the depth information can be derived by calculating the time it takes for a projected light beam to reflect from an object back to a sensor (i.e., time-of-flight). Time-of-flight is similar to the principles of radar, except that a light pulse is used instead of an RF pulse.

In each of these exemplary embodiments, an imaging subsystem with at least one image sensor is used to capture an image (or images) of an object (or objects) in a field-of-view. A dimensioner can also measure the space that is not occupied by objects. For example, the volume left in a delivery truck, the dimensions of an empty concrete form, or the volume between attic beams. In each of these examples, a volume calculation would be helpful to insure proper filling.

Importantly, the accuracy for dimensioners depends on the measurement geometry and the sensor-subsystem specification (e.g., resolution, field-of-view, etc.). This accuracy may change depending on the measurement conditions (e.g., the measurement geometry).

Measurement geometry refers to the dimensioning-measurement setup (e.g., the spatial relationship between the dimensioning system and the object). As shown in FIG. 1, a dimensioning system's 2 field-of-view 3 is placed in front of an object for dimensioning 1. The object is at a range 4 (i.e., the distance between the dimensioning system and the object) so that it is completely encompassed within the field-of-view 3. Typically, three sides must be visible to the dimensioning system 2 for volume measurements. This means that the edges 5,6 of an object surface 9 should create an angle 7 with respect to the dimensioning system as shown in FIG. 1. In other words, an object surface 9 must be visible to the imaging subsystem for sensing. For example, when using a projected light pattern to sense depth information (e.g., structured light), an object's side must reflect some minimum fraction of the light pattern in order for depth information for that surface to be derived. In the exemplary case shown in FIG. 1, the object 1 can be rotated 8 to adjust this angle 7. A possible embodiment of the present invention is to provide feedback to facilitate the adjustment (e.g., rotation, range, etc.) of the measurement geometry in order to make sensing possible. In other words, the dimensioner may recognize poorly positioned objects and provide prompts alerting a user and offering adjustment messages to make dimensioning possible (and/or more accurate).

Dimensioning-measurement confidence may be based on calculations using the received image. These calculations generate a confidence level for the dimensioning measurement. Specifically, calculating dimensions one pixel to either side of an object edge provides the range of confidence for the dimensioning measurement. For example, when the side surface 9 of the object 1 is viewed obliquely (as shown in FIG. 1), a single pixel consumes a larger portion of the image plane. Thus, calculating the surface dimensions one pixel to either side of an edge will show a variation in dimension measurements that is large with respect to the dimensions of the side 9. Conversely, if a box side is viewed nearly straight on, then calculating surface dimensions one pixel to either side of an edge will show only a small variation with respect to the dimension of that side. As a result, there is a higher confidence level associated with a dimensioning measurement for a side viewed nearly straight on than for one viewed obliquely.

The range 4 is important for dimension measurement accuracy. In general, the closer the object is to the dimensioning system, the greater the accuracy of the measurement. Put another way, the increment of measurement is smaller for closer objects than for objects further away. This can be understood by considering the field-of-view's size with respect to the object. If the dimensioning system, for example, samples depth evenly over the field-of-view 3, then small, faraway objects that occupy a small fraction of the field of view will have reduced depth sampling and therefore may be measured with less accuracy.

Guidelines for dimensioning measurements are provided for the United States by the National Institute of Standards and Technology (NIST) in the “NIST Handbook 44” 2013 edition and is therefore hereby incorporated by reference. These guidelines state that for a measurement to conform to the standard, the minimum object dimension must be at least twelve (12) times the smallest increment of length that can be measured.

To help understand the NIST guidelines consider the following exemplary dimensioning scenario. Two boxes at a distance of twelve feet (12′) are to be measured using a dimensioning system. One box (i.e., box-one) is a cube of thirty-nine inches (39″) per side and the other box (i.e., box-two) is a cube of thirteen inches (13″) per side. Based on the range and the details of the imaging subsystem, suppose that the smallest increment of length that the exemplary dimensioning system can measure at this range (i.e., the increment of measurement) is 2 inches (2″). Box-one may be measured accurately and a typical measurement might be thirty-eight (38″) or forty (40″). Box-two may return a measurement (e.g., 12″ or 14″) but this measurement would not be in conformance with the standard for accuracy since box-two is only thirteen inches (13″) per side and the minimum length that can be measured (and still be in conformance with the standard) must be twelve times the smallest increment (i.e., 12×2″=24″).

Now suppose that the measurement geometry in this exemplary dimensioning scenario is changed so box-two is only three feet (3′) away from the dimensioning system. At this range the smallest increment of length that can be measured for this system is one-half an inch (0.5″). Box-one may now be measured in conformance with the standard and a typical measurement might be thirteen inches (13″).

This example shows that while a measurement may be returned from a dimensioning system for all reasonable measurement geometries, the measurement returned may not be in conformance with the standard. This may not always be obvious to a user. What is needed is a dimensioning system that monitors this relationship between measurement accuracy and standard and that can provide a user with feedback messages concerning measurement-conformance. Further, if a measurement is impossible then this same system may also notify the user of this.

It should be noted that while particular sensor technologies and standards have been discussed so far, the concept disclosed could be applied any dimensioning system that uses a camera and could be applied using any reference or standard as a basis of conformance. Further, while handheld dimensioning systems are the most obvious type of dimensioning system that could utilize the measurement-conformance feedback, any dimensioning system that has an adjustable measurement geometry could make use of this as well.

A block diagram of an exemplary embodiment of a dimensioning system is shown in FIG. 2. A handheld dimensioner 2 is positioned so that an object 1 may have its dimensions (e.g., volume) measured optically. To accomplish this measurement, the dimensioner 2 utilizes a variety of subsystems.

An imaging subsystem 10 captures depth information of the object 1 in a field of view 3. To accomplish this, the imaging subsystem uses an imaging lens 11 to focus a real image of the field of view onto an image sensor 12 to convert the optical image into an electronic signal. The image sensor 12 may be a charge coupled device (i.e., CCD) or a sensor using complementary metal oxide semiconductor (i.e., CMOS) technology. The image sensor 12 typically includes a plurality of pixels that sample the real image and convert the real-image intensity into an electronic signal. A processor (e.g., digital signal processor (DSP)) 13 is typically included to facilitate the formation of the digital image.

The creation of depth information is facilitated with a second element in the imaging subsystem that either transmits an optical signal (i.e., projector) or images a scene (i.e., sensor). The lens 14 for the sensor (or projector) 15 is typically configured into a stereo arrangement with the imaging lens 11 to allow for the collection of depth information (e.g., measurement of distances) using the principle of parallax. The sensor (or projector) 15 is typically communicatively coupled to the DSP 13 which facilitates is control, function, and communication.

A control subsystem 20 is communicatively coupled to the DSP 13 used by the sensor (or projector) 15 and the image sensor 12. The control subsystem 20 includes one or more processors 21 (e.g., one or more controllers, digital signal processor (DSP), application specific integrated circuit (ASIC), programmable gate array (PGA), and/or programmable logic controller (PLC)) to configure the imaging subsystem for the dimensioning data collection and then perform the processing necessary on data collected to generate dimensioning measurements and feedback. The processor 21 is typically configured by processor-executable instructions (i.e., a software program) stored in at least one non-transitory storage medium (i.e., memory) 22 (e.g., read only memory (ROM), flash memory, and/or a hard-drive). The processor-executable instructions, when executed by the processor 21 configures the processor to: (i) receive images from the image sensor(s), (ii) compute a measurement geometry, (iii) derive a measurement accuracy, (iv) identify a conformance criteria, (v) obtain a dimension measurement, and (vi) compare the dimension measurement to the conformance criteria in order to generate measurement-conformance feedback.

The dimensioning system 2 may also include a user-interface subsystem 30 to display dimension measurements (e.g., linear dimension or volume) and measurement-conformance feedback. In some embodiments, the user-interface subsystem 30 may also facilitate the selection of dimensioning surfaces for dimensioning.

The dimensioner 2 may also include a communication subsystem 40 for transmitting and receiving information to/from a separate computing device or storage device. This communication subsystem may be wired or wireless and may enable communication with a variety of protocols (e.g., IEEE 802.11, including WI-FI®, BLUETOOTH®, CDMA, TDMA, or GSM).

The subsystems in the dimensioner 2 are electrically connected via a couplers (e.g., wires or fibers), buses, and control lines to form an interconnection subsystem 50. The interconnection system 50 may include power buses or lines, data buses, instruction buses, address buses, etc., which allow operation of the subsystems and interaction there between.

A block diagram representing an exemplary method to generate measurement-conformance feedback for a dimension measurement is shown in FIG. 3. The method begins with the step of capturing of an image using a dimensioning system 60. The image may contain one or more objects for dimensioning and covers a field of view. From this image, a measurement geometry may be computed 61. The measurement geometry includes information such as, range, object-surfaces, and object-orientation. From this information, the measurement accuracy may be computed 62. The accuracy includes the smallest increment of length that can be measured. This accuracy can be used to identify the conformance criteria 63. This is the criteria stipulated by a standard (e.g., NIST Standard) or other reference to assure the accuracy of a measurement. Next the image (or images) captured can be used to compute a dimension measurement 64. The dimension measurement may include object volume or a linear dimension like the length of an object surface. The dimension measurement may also include measurements of multiple objects within the field of view. At this point, the dimension measurement is compared to the conformance criteria and a decision is made 65. If the dimension measurement complies with the conformance criteria, then a conformance message may be generated 70 along with the dimensioning results 71. If, on the other hand, the dimension measurement is found not to comply with the conformance criteria then a non-conformance message may be generated 80. Then, to facilitate a good measurement, a necessary adjustment for the dimensioning system (relative to the object) may be computed 81 (e.g., move closer/farther-away or move left/right). If no solution is found, then an error message may be generated 82. This error may arise for dimensioning scenarios such as: objects with dimensions outside the range of the dimensioning system, measurement geometries beyond the dimensioner's capabilities (i.e., too far), or poor lighting. If a solution is found, however, an adjustment message may be generated 83 to help a user adjust the measurement geometry 84.

Once the dimensioning system is configured with a new measurement geometry, then the process 60,61,62,63,64 may repeat and the new dimensioning results can be compared with the computed conformance criteria for the new measurement geometry. The entire process continues until a conforming dimensioning result is found or found to be unobtainable. Several iterations may be required to reach a conforming measurement, but in the end, the user is assured that the measurement calculated is accurate and conforms to the standard.

To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation. 

The invention claimed is:
 1. A method for generating a confidence level for a dimension measurement, comprising: capturing, using an image sensor, an image of an object in a field of view; calculating, using the captured image, at least one first dimension of the object from a first edge of the object to a second edge of the object; calculating, using the captured image, at least one second dimension of the object from one pixel on a first side of the first edge of the object to the second edge; calculating a difference between the at least one first dimension and the at least one second dimension; and generating the confidence level based on the difference in the at least one first dimension and the at least one second dimension of the object.
 2. The method of claim 1, wherein a higher confidence level indicates higher accuracy of measurement.
 3. The method of claim 1, wherein, prior to generating the confidence level, the method further comprises: computing, with a processor, a measurement geometry using the at least one image, the measurement geometry being an orientation and spatial relationship between the image-sensor and the imaged object; and deriving, with the processor, a measurement accuracy corresponding to the measurement geometry.
 4. The method of claim 3, wherein capturing the at least one image of the object in the field-of-view comprises capturing the at least one image as viewed along two different lines of sight.
 5. The method of claim 3, further comprising, changing the confidence level by adjusting the measurement geometry.
 6. The method of claim 5, wherein changing the confidence level comprises adjusting an angle of the imaged object with respect to the image-sensor.
 7. The method of claim 3, further comprising: identifying, with the processor, at least one conformance criterion based on the measurement accuracy, the at least one conformance criterion being a predetermined measurement accuracy standard or reference; obtaining, with the processor, a dimension measurement using the at least one image; comparing, with the processor, the dimension measurement to the at least one conformance criterion; and generating, with the processor, measurement-conformance feedback corresponding to results of comparing the dimension measurement to the at least one conformance criterion.
 8. The method of claim 3, wherein capturing the at least one image comprises capturing a structured light pattern.
 9. The method of claim 3, wherein capturing the at least one image comprises capturing the at least one image using time-of-flight sensors.
 10. The method of claim 3, wherein computing the measurement geometry using the at least one image comprises computing a distance between the object and the image-sensor.
 11. The method of claim 3, wherein computing the measurement geometry using the at least one image comprises computing information related to range, object surfaces, and object orientation.
 12. The method of claim 7, wherein obtaining the dimension measurement comprises obtaining one of a volume, a length, and a surface area.
 13. The method of claim 7, wherein generating the measurement-conformance feedback comprises generating one of a conformance message, a non-conformance message, and an error message.
 14. The method of claim 7, wherein generating the measurement-conformance feedback comprises generating an adjustment message, wherein the adjustment message comprises instructive prompts to facilitate the adjustment of the measurement geometry in order to achieve measurement conformance.
 15. The method of claim 7, wherein generating the measurement-conformance feedback comprises generating a dimension measurement and a conformance message, the conformance message indicating whether the dimension measurement conforms or does not conform to the at least one conformance criterion.
 16. The method of claim 7, wherein generating the measurement-conformance feedback comprises generating an indication that the object cannot be measured in compliance with the at least one conformance criterion when less than three surfaces of the object are visible to a dimensioning device performing the dimensioning measurement.
 17. A method for generating a confidence level for a dimension measurement of an object, comprising: capturing, with an imaging system, an image of the object in a field-of-view; calculating, from the captured image, at least one first dimension of the object from a first edge of the object to a second edge of the object; calculating, from the captured image, at least one second dimension of the object from one pixel on a first side of the first edge of the object to the second edge; and calculating a difference between the at least one first dimension and the at least one second dimension, wherein the smaller the difference between the at least one first dimension and the at least one second dimension, the higher the confidence level in the dimension measurement.
 18. The method of claim 17, wherein the higher the confidence level, the higher accuracy of the dimension measurement.
 19. The method of claim 17, further comprising adjusting a measurement geometry if the confidence level generated using the image is non-conforming with a conformance criterion, the measurement geometry being an orientation and spatial relationship between the imaging system and the object.
 20. The method of claim 19, wherein adjusting the measurement geometry comprises adjusting an angle of the object with respect to the imaging system. 